Method of coating stitched fabric



Dec. 23, 1947. 1. Y. GOLDMAN 2,433,270

METHOD OF COATING STITCHED FABRIC Filed April 6, 1944 2 Sheets-Sheet l 91 /IN VEN TOR.

Dec. 23, 1947. 1. Y. GOLDMAN 7 12,433,270

METHOD OF COATING STITCHED FABRIC Filed April 6, 1944 2 Sheets-Sheet 2Patented Dec. 23, 1947 UNITED STATES PATENT OFFICE 2,433,270 Mirriiol)oF coA'rrNG STITCHED FABRIC Ida Y. Goldman, Brooklyn, N. Y. ApplicationApril 6, 1944, Serial No. 529,729 1 Claim. (01. 117 .6a)

1 This invention relates to articles which combine certain waterabsorbing and water resisting characteristics, and has further referenceto methods of making such articles.

One object of the invention is to provide a sheeting the component partsof which are interconnected to form a one-piece structure to be sold inthe trade as a garment producing fabric, which sheeting has the capacityfor the rapid and substantial absorption of liquids to thus increase thecomfort ef the wearer, combined with the characteristic of arresting theflow of liquids through the heeting where the absorption capacitythereof should be exceeded or where a time element is required fordistribution of the liquid for uniform absorption by the sheeting.

, The particular utility of such a sheeting will be instantly apparentby considering its embodiment in a diaper. From the standpoint of themanufacturer of the diaper, he need merely cut the sheeting into blanksand bind the edges to complete the article. From the point of view ofthe user, the diaper can quickly and fully absorb all liquids,substantially prevent leakage and soiling of bedding and outer garmentand avoiding wetting of exposed portions of the body of the child, thusreducing the opportunity for chilling thereof, with resultant colds.Such a diaper, moreover, is highly compact, remains in proper positionwithout slippage of various layers or sheets, and is quick and easy toapply. The Waterproofing component is soarranged that it does notprevent complete and rapid absorption of liquids, but arrests the spreadthereof, prevents too rapid evaporation with undue cooling of the childsbody, and always presents a neat and clean exterior appearance, free ofdiscoloration. It will thus appear that the diaper is soft, warm, and

comfortable to the tender skin of a baby.

The manufacturer of the sheeting may cheaply and quickly construct theSame by the use of quilting machinery, a water resistent coating beingapplied by him preferably thereafter.

Another object of the inventionis to furnish an improved article of thecharacter described wherein a quilt-like sheeting is provided with anexterior coating of water resistent material that completely closes andseals the openings at the multitude of stitches. v

Where cotton batting is used as a filler, it is of considerableadvantage to close the stitch openings, especially because the cottonefiiciently transmits liquid by capillary action and because the body ofthe cotton shrinks when it is fully wetted, permitting considerableslackening of the stitches.

Another object of the invention is the provision of an improvedquilt-like article having an impregnating coating on a side closing thestitch openings in combinationwith a very soft, completely-fillingbatting which provides a: backin for the stitch openings to permittheplastic coating material to actually seal the stitch openings insteadof only partly easing the same. I

Another object of the i" :entiohfstd provide an improved article of theattire set forth wherein the absorbent side may be relatively coarse forrapid absorption of liquid, and the other side densely woven to requirea minimum of coating material and to render the same water proof withonly one or two coats, so that the article may be cheap and efficient ina high degree.

A further object of the invention is to provide improved methods ofmaking an article ofthe character described to assure sealing of thestitch openings without interference by the stitches; to avoid pullingand distortion of the stitches; and to assure uniform coating of thetextile at points varying in distance from the stitches.

It has been observed that a plastic for waterproofing a textile must be,accurately and uniformly applied on its very first coat, and if smallparts are not properly coated, solidification of the first coat mayprevent rectification by a subsequent coating, and hence the inventionaims to provide the necessary high degree of uniformity.

Other objects and advantages of the invention will become apparent asthespecification' proceeds.

With the aforesaid objects in View, the invention comprises the novelfeatures; combinations and arrangements of partshereinafter described intheir preferred embodiments, pointed out in the subjoined claim, andillustrated in the annexed drawing, wherein like parts are'designated bythe same reference characters throughout the several views.

In the drawing:

Figure 1 is a fragmentary plan view of a sheeting embodying theinvention, with parts removed to show its components.

Fig. 2 is an enlarged sectional view;

Fig. 3 is a fragmentary greatly enlarged view of a portion of thearticle. l

Fig. 4 is a plan view, partly in perspective, showing a garment, such asa diaper, embodying the novel fabric.

Fig. 5 is a diagrammatic viewshowing a method of practising theinvention.

Fig. 6 is a similar view showing modified method.

The advantages of the invention as here outlined are best realized whenall of its features and instrumentalities are combined but, usefulembodiments may be produced involving less than the whole.

It will be obvious to those skilled in the art to which the inventionappertains, that the same may be incorporated in several differentconstructions. The accompanying drawing, therefore, is submitted merelyas showing a preferred exemplification of the invention.

Referring in detail to the drawing, I denotes an article such as asheeting, embodying the invention. The same may include a quilt-likebody having opposed sheets of material I I, :2, between which isdisposed a batting I3 of intertwined, fibrous, moisture absorbentmaterial, such as a cotton or other vegetable fiber. Interconnecting thesheet members II and I2 is a field of stitching coextensive with thearticle, and including spaced intersecting rows of stitching I4extending preferably diagonally to the weave of the fabrics II, I2 for areason hereinafter described. This stitching passes through the fillerI3 and thus affords a unitary structure, and prevents shifting of thefilling. The fabric II is intended to be a relatively coarse fabrichaving large interstices through which water can readily pass, and yetsufliciently small to confine the fibers of the padding I3. The fabric II may be an open mesh knitted material, but the best results areobtained with the use of a textile whose weave may be approximately 30by 40. To the contrary, the fabric I2 is preferably densely woven andmay have, illustratively, a weave of 60 by 80 so as to be adapted to berendered waterproof by a minimum application of plastic. Of course thefabrics II and I2 may both be alike, in which case the weave may beintermediate of the coarse and dense weaves above mentioned. Withconventional cotton batting and ordinary thin textiles, the thickness ofthe article In need not exceed about one-eighth of an inch, but it maybe as little as one-sixteenth and as much as threesixteenths of an inchand realize the objects of the invention. 0n the outer face of thetextile I2 is a coating I 5 of water resistant material such as a vinylresin plastic, this coating having an average thickness preferably notexceeding a few thousandths of an inch. This plastic is impregnated intothe textile I2 and into the thread of the stitching I4, and issufficient to fully close the interstices of the cloth and the holestherein produced by the needle in forming the stitching I4. In fact, theexternal parts of the stitching thread may adhere to the cloth I2 byreason of the plastic. These results may be accomplished by usingapproximately one to three ounces of the plastic per square yard of thearticle ID. For some purposes, an article such as I0 may be made by theuse of a precoated fabric I2, but leakage through the stitch holes willoccur especially because the batting, if soaked with liquid and thensqueezed as by pressure of the wearers body, will force liquid throughthe stitch holes.

It is noteworthy that the cotton batting I3 whose fibers are very fine,will closely extend around the threaded portions I6 within the articleI0 and hence engage in or at the stitch holes I! thus affording abacking I8 for the application of the plastic. This backing is increasedby the compression of the batting due to the stitching.

This nap-like backing is important because without it, the stitch holeswould not be closed unless an exceptional weight of plastic were used.Without a proper backing, the plastic would merely form a rim or liparound the edges of the holes, if a reasonabl thin coating is to beused, or a minimum number of applications of the coating. Satisfactoryresults may be accomplished even if only moderate stitch tension isused. Since the thread becomes united to the coating 55 slippage of thethread is avoided, as where the cotton batting becomes soggy withmoisture and loses volume, causing a reduction in stitch tension. Suchslippage, if it occurred, would eventually enlarged the stitch holes. Bythe instant structure, the plastic coating 25 is continuous over thefabric I2 and the stitching I6 affording a fairly smooth and uniformouter surface which will not collect dirt and the like.

It will now be seen that the article I8 constitutes a. sheeting welladapted to be made by a quilt manufacturer with his existing equipment.Such manufacturer may then apply the coating I5 to complete the article.This article it may be sold as a sheeting to be cut and made intogarments by ordinary methods. The article has the capacity for absorbinga substantial quantity of liquid at high speed due to the character ofthe cloth II and the cotton I3. The waterproofing coating I5 cooperatesto prevent the liquid from striking through and to arrest and deflectthe liquid for distribution in the cotton batting. The sheeting I0 isvirtually a one-piece structure, whose parts will not shift, and whichis capable of being easily sewn and worked to produce garments ofsubstantial strength and durability.

In Fig. 4 is shown an article such as a diaper 20 embodying the novelfabric. Otherwise the same may be of an conventional construction, andis preferably shaped for at least a partial form fit. It may have a bodyembracing wall 2! made of the sheeting I0. For this purpose, the latteris merely cut to shape and a binding 22 is stitched to its edges toenclose the padding I3 and finish the article. Any suitable fasteningmeans may be secured to the article such as tapes or snap fasteners 23.Thus the diaper consists virtually entirely of the sheeting Ill andaffords the protection thereof around the body and crotch of the childwith proper leg receiving openings at 24. The liquid will be rapidlyabsorbed and distributed in the filling I3 before it can readily leakout through these openings. The absorbent inner face of the diaper issoft and smooth to the skin of the child. The water resistent outer facewill not show soiling or leakage, with the coating I5 resisting wear andpreventing rupture of the stitches I4 if the child is sitting on orsliding itself along the floor. The diaper is of a good insulatingcharacter for warmth, and prevents excessive evaporation of liquid andconsequent chilling of the childs body. It may be readily washed sinceit fully opens up'fiat, and is then fairly quick drying. Diiferent coloreffects may be obtained since the inner cloth I I may be white while theouter fabric I2 may be pink, or the plastic coating may itself becolored. The appearance is thus very neat, the stitching being partiallyobscured by a translucent coating as suggested in Fig. 1, but thecoating may also be substantially opaque as by using a sufiicient color.

The sheeting II] is susceptible of embodiment in various other articles,such as under-arm shields and in many other relations where excessiveperspiration is to be absorbed. It may be made into head coverings to beused by women who go to bed after washing their hair. These and otherinstances are intended to be merely illustrative of the advantagesobtainable with the invention.

In Fig. 5 is shown an apparatus 25 to illustrate a preferred method ofmaking the article It, preferably with reference to the provision of thecoating l5. Here a sheeting 26 is shown consisting of the article Illless the coating Hi. This sheeting is trained over suitable rollers 21,28 and is fed along under tension applied by any suitable rollers notshown. Intermediate of the rollers 21, 28 the sheeting 26 is permittedto sag to form a trough as at 29 for receiving coating material inplastic condition as at 30. Acting on this plastic is a doctor blade 3!which is vertically and angularly adjustable. Disposed within the trough29 in advance of the doctor blade is a means for working the plasticinto the upper face of the sheeting 26 to enter the stitch openings I1and to penetrate into and around the exposed part of the thread of thestitching l4, and to penetrate the textile I2 to close the poresthereof. The means referred to may include rollers 32, 33 rotating inopposite directions in order to approach the exposed stitch threads fromopposite sides to thoroughly work in the plastic in course of a singlerun or coating operation. In other words the plastic is kneaded into andagainst the fabric and the stitching, with a shifting and turning of theexposed stitch thread and a forcing of the plastic from differentdirections before any part of the plastic has had an opportunity to set.A complete adequately penetrative action is assured by succeedingoperation of the different kneading rollers 32, 33. The second roller 33applies the plastic rightward against the direction of the action of thedoctor blade, so that there are thus three successive plastic applyingactions. The doctor blade performs a final Working-in of plastic,smooths the coating and scrapes 01f excess plastic. The coated product34 now enters a dryer, not shown, in which the coating is hardened toproduce the sheeting Ill.

By diagonally disposing the lines of stitching, excessive pull ordistortion at the stitch threads is avoided, and yet there is a lateralcomponent of force applying plastic to and at the threads. Hence it isbetter to position the lines of stitching on the bias than parallel orat right angles to the length of the goods.

By reason of the fine cotton filling l3, as previously described inconnection with Fig. 3, a suitable backing I8 at the stitch openings I1is provided to support the plastic to close and seal these openings.Without this backing, the plastic cover would either break like abubble, or never deposit except at the edges of the openings. In thatsense, the provision of the cotton batting may be regarded as an elementof the process or method of coating.

If the first coat is imperfect, it is difficult or impossible to closeany openings that may be left by applying succeeding coats. The coatingl5 may be applied in one or several coating operations.

The tensions exerted by the different rollers 32, 33 may or may notneutralize each other, but the roller 33 may travel much faster than theroller 32, because roller 33 rotates counter-clockwise.

In Fig. 6 is shown a modified apparatus 35 lllustrating a differentmethod embodying the invention. This apparatus includes feed or guiderollers 36, 31 acting on a fabric 26a like that at 26, with a doctorblade 38 at the roller 31, and a kneading means comprising opposedrollers 39, 40 like those at 32, 33. In operation, the method involvedis like that for the apparatus 25, with the exception that the doctorblade is applied at a point where the fabric 26a is convexed in order tostretch the fabric l2 more than the fabric II, this result being aidedby the intermediate filling l3. This assures perfect smoothness for thefabric l2 that is being coated, and causes the portions of the stitching14 that are exposed above the fabric l3 to be stretched taut so that theblade may ride with perfect smoothness and evenness over the stitchesand over the adjacent parts of the fabric l2.

With both methods, the stitch holes or large interstices in a verycoarse Weave are closed by the plastic entering thereinto and actuallybonding onto the adjacent cotton padding which serves as a backing forthe plastic, this backing being pressed against the holes by thestitching. Thus a difficult problem is overcome, and even garment seamscan be waterproofed at the stitches by disposing a thin line of softcotton batting within the seams and then stitching along that line toconstruct the seam, and finally coating.

It is thus seen that there are provided new articles of manufacture andimproved methods of making the same to realize all the various objectsand advantages of the inventions disclosed.

I claim:

The method of coating a stitched fabric so as to impregnate the latterand close the holes formed by the stitching, including applying plasticcoating material to the fabric at one side thereof, kneading the plasticmaterial into the fabric by moving the plastic first in one directionthen in a different direction at an angle to the direction of thestitches, and then scraping the fabric to remove excess of plasticmaterial, the kneading and scraping being performed in a single coatingoperation and before the plastic that is being worked has had anopportunity to harden.

IDA Y. GOLDMAN.

REFERENCES CITED The following references are of record in the file ofthis patent:

UNITED STATES PATENTS Number Name Date 342,494 Baldwin May 25, 1886882,832 Moss Mar. 24, 1908 1,289,507 Mason Dec. 31, 1918 1,345,693 PyeJuly 6, 1920 1,465,092 Respess Aug. 14, 1923 1,533,973 Cohen Apr. 14,1925 2,016,601 Hlavaty Oct, 8, 1935 2,117,432 Linscott May 17, 19382,146,664 Wolff Feb. 7, 1939 2,364,505 Bennett Dec. 5, 1944 FOREIGNPATENTS Number Country Date 453,267 Great Britain Sept. 8, 1936

